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Partnership with Bosch Accelerates Production
Endangered Species™ Chocolate expects more than a 230 percent boost in output by using Bosch’s Pack 401 horizontal flow wrapper, enabling it to meet increasing demand for its chocolate bars. As evidenced by its name, the premium chocolate company donates 10 percent of its net profits to species and habitat conservation efforts.
The company has been using Bosch machines since opening in 1993. As more and more consumers were craving its 0.35-ounce Organic Chocolate Squares, known as Chimp Mints and Bug Bites, Endangered Species needed to increase production capacity. The Pack 401 enabled production to jump from 120 pieces per minute to 400 pieces per minute.
“The Pack 401 wraps our products faster than we can currently produce them,” said Bryan Fuller, Director of Operations, Endangered Species. “This positions us for our anticipated growth over the next few years.”
Previously, defective packaging had to be manually sorted and discarded. The Pack 401 features sensors that automatically detect and reject inadequate products and packaging, such as empty packages, uncut packages, or packages with film splices, which increases efficiency and saves on labor costs.
“Our conservation mission is the core of our organization and we fully trust that Bosch’s technology will produce results,” Fuller added. “Higher profits and reduced waste mean more donations to our not-for-profit partners.”
As the company experienced tremendous growth in production, it needed a machine with simplified cleaning and maintenance to ensure product safety and remove all traces of allergy-causing ingredients. “The Pack 401 is an expertly planned machine – every section is easy to access and clean,” said Fuller.
“We always enjoy helping our customers reach their production goals and it’s even sweeter when this also benefits important causes,” said Paul Garms, Marketing Manager, Bosch Packaging Technology.
Endangered Species’ previous solution required that the chocolate squares be manually transferred from their molds to the primary packaging machine. The Pack 401 automatically directs the chocolates from the mold line to the flow wrapper without human intervention, allowing the company to redirect labor to higher skilled positions.
We invite you to walk through our Pack Expo 2012 booth in a new 3D interactive website (www.BoschPackagingBooth.com). Our new “Virtual Booth” technology makes it feel like you are right on the show floor with 3D machine views, video from the show, and the ability to download brochures and contact Bosch.
See what you missed at our booth, or share with your colleagues the exciting new machines you saw. The virtual booth includes 17 different displays that you can interact with. Navigating the booth is easy. Simply click on the left or right arrows to move around the booth and then select the machine or kiosk that is of interest to you. It’s a great way to explore new packaging technology without leaving your office!
Select a machine or kiosk to see a close-up view like this with descriptive text. Buttons on the bottom of the screen allow you to watch a video, go to the product page on the Bosch website, request a quote, contact Bosch, or request a brochure.
To increase outputs or lower manufacturing costs, manufacturers are often challenged with the decision of selecting between robotics or product distribution conveyors when opting to automate their lines. As a supplier of robotics, conveying technologies and integrated packaging lines, Bosch discusses the criteria in selecting an optimal feeding solution in a new white paper – “Packaging Line Automation – Robotics or Product Distribution Conveyors?”, recently featured on Snack Food and Wholesale Bakery. The white paper provides unbiased advice for manufacturers and highlights key considerations for choosing between robotics and product distribution conveyors for feeding.
For example, the paper advises on different pack configurations, such as for a simple bar package or a more complicated cookie stack. For more information, click on the link above.
The United Fresh 2012 show honored Bosch’s new Pack 301 IN inverted flow wrapper with the Best New Packaging/Processing Equipment award. The award was voted on by United Fresh, AMI, and FMI attendees at this year’s joint conference held in Dallas, TX May 1-3. As an inverted flow wrapper, the Pack 301 IN gently transports product by carrying it on top of the film from the former through the cutting head minimizing jams and ensuring superior package appearance. Due to this gentle handling, the machine is ideal for soft products, multi-packs, and other products that are difficult to handle using a traditional upright flow wrapper design, like fresh produce.
If you missed the Pack 301 IN at the United Fresh 2012 show you can see it in this short clip featured on United Fresh TV:
The Pack 301 IN features a unique modular film backstand that can be located in various positions relative to the infeed and wrapper This allows users to optimize the film path, avoiding unnecessary film path length, resulting in supreme package appearance, minimal film waste, and few rejects.
The fresh produce industry gathers this week in Dallas, TX for the annual United Fresh show. This year the show is co-located with AMI’s International Meat, Poultry and Seafood Convention; drawing an expected crowed of over 25,000 attendees. We invite you to visit the Bosch booth (#12300) in the United Fresh Tech section to see our new Pack 301 IN inverted horizontal flow wrapper. The Pack 301 IN automates the packaging of fresh produce like spring onions, carrots, romaine lettuce hearts, celery, cucumbers and other fresh produce that have a size and shape conducive to flow wrapping. Its film backstand has a modular design that allows users to customize the film path to optimally transport produce into the flow wrapper while maintaining control of the product, minimizing jams and ensuring superior package appearance. Also on display at the Bosch booth will be the Doboy B-550 band sealer and the SVE 2515 vertical form-fill-seal bagger with ultrasonic sealing.
If you’re unable to attend the show, you can watch video from the show floor at United Fresh TV. Last year, Bosch’s Doboy Stratus flow wrapper was highlighted by United Fresh TV. Watch the clip below to see Jon Otto, product manager, explain the flexibility of the Doboy Stratus and demonstrate the machine by packaging a tray of two bell peppers.
Having trouble maintaining the temperature in your wrapper can lead to inappropriately sealed packages, burned packaging and overall just a big quality headache. If you are experiencing a problem with your temperature control our technical experts recommend that you do a thorough check of your collector rings. Although other factors could also be contributing to your temperature control problem, these are some quick, easy, and relatively inexpensive things you can check and replace early in the process.
For safety reasons ensure that you have first disconnected power to the machine. Open the front panel and remove the guard.
First check the strength of the springs. If they are not holding the silver braids tightly to the ring, they could be causing your temperature control issue and would need to be replaced.
If the springs are still taut, check the silver braids for obvious wear. You will notice an obvious thinness to the braids and they will no longer be making good contact with the collector rings. Again, if you notice any of these issues its time for a replacement of the silver braids.
Next check the carbon brushes. Remember though, the caps on the carbon brushes are spring loaded and have a tendency to get away from you. Remove the cap carefully and check the length of the brush, if less than approximately a half inch that part will also need to be replaced. Also when checking the brushes (or when replacing them) check that the brushes are contacting the center of the rings. If not, adjust the ring assembly to the center the brush.
Also at this time make sure that all four wires attached to the end of the collector ring are secure and undamaged.
And last but not definitely not least, check to make sure the collector ring is securely attached to the shaft. The collector ring set screw should be tightened to 10-12 inch pounds of pressure.
While the collector rings are exposed and the power off go ahead and check the ring surfaces for any minor scuff marks as well. These can easily be cleaned up by carefully buffing them out with a standard pencil eraser.
If the temperature control issue persists contact your Bosch Packaging Services customer support contact to further assist you with the problem.
Be prepared for this, and other potential issues with your packaging machine with Bosch Packaging Services Preventive Maintenance kits. We have compiled kits with OEM parts and recommended replacement intervals to take the guesswork out of preventive maintenance and eliminate time consuming ordering of individual small parts. Save not only on shipping costs but also 5% off the price of the individual parts when ordered as a complete kit.
For more information on all of our preventive maintenance offerings, including Preventive Maintenance Service Agreements, download the brochure or Contact Us.
*currently only budgetary pricing is available. For specific pricing for your machines contact your Bosch Packaging Services customer representative with the machine serial number and allow for at least a two week lead time.
Product distribution conveyors feeding two horizontal flow wrappers
When manufacturers opt to automate their lines to achieve increased outputs or lower manufacturing costs, they often are challenged with the decision of selecting robotics or product distribution conveyors. Both technologies have their place in modern packaging lines. As a supplier of robotics, conveying technologies, and integrated packaging lines, Bosch understands the criteria needed to select an optimal feeding solution and can help manufacturers take a holistic and comprehensive view.
In a recent white paper, we identified three characteristics of your packaging line and product to evaluate when choosing between robotics and conveyors:
- pack configuration
- product characteristics
- operating environment
3 arm delta robot feeding a horizontal flow wrapper
First, manufacturers must consider the complexity of their pack configuration, as well as the number and orientation of products within a package. Conveyors offer speed advantages for simpler pack configurations like single candy bars while robotics are better suited for more complex styles like multipacks. Next, product characteristics should be evaluated when investing in new automated feeding equipment, including whether the product is delicate and needs to be handled gently or more rugged and can withstand harsher conditions. Finally, the white paper discusses how sanitation, floor space and other environmental factors in the manufacturing facility affect the choice between robots and product distribution conveyors.
Download your copy of our new packaging automation white paper from the Bosch website:
http://www.boschpackaging.com/nrd/automation
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Our machine experts recommend following the steps below every thirty days for the improved maintenance of your machine.
1) Check the cutting head drive chain condition and tension, lube when required
2) Inspect all prox and photo eye sensors operation and alignment
3) Inspect collector ring assy’s cutting head and finwheels for carbon or debris build up, brush alignment, condition of silver braids, and replace any worn parts.
4) Check thermocouple and power wire connections on collector ring assy’s, crimpers and finwheels.
5) Inspect main electrical component wiring and connections
6) Check backstand film rollers for free rolling movement, PFR drive roller and pinch roll for wear and pressure adjustment.
Upgrades are also an important part of maintaining your machine. Bosch modernizations work to improve the efficiency of your machine by upgrading your machine with state of the art technologies.
With Bosch Packaging Service’s Allen Bradley and WinPack Controls upgrades you can completely upgrade your current control panel with either Allen Bradley’s ControlLogix Processor or Beckhoff’s Industrial PC Controller with modular I/O. You can find specific offerings for both the Allen Bradley and Beckhoff upgrade in our product brochures.
For more information on our products and services, or to be entered into our monthly drawing for a Bosch power tool, Contact Us.
